Heat exchange manifold connector

ABSTRACT

A manifold kit for a solar heat exchanger of the type having a mat of tubes connected to inlet and outlet manifolds. Each manifold has at least one, preferably 5, groups of spigots tubes with three spigots in each group. Each group of spigots comprise a base fitted to the manifold a planar region on said base and a plurality of tubular spigots projecting from said planar region. A connector is adapted to receive a group of 3 heat exchanger tubes in one end and adapted at the other end to connect to a group of 3 spigot tubes on the manifold. This arrangement avoids the need for special tools during installation and the group of heat exchanger tubes can be easily fitted with the connectors and then snapped onto the manifold.

This innovation relates to improvements in the installation of solar heating heat exchangers and in particular to a manifold and connector arrangement.

BACKGROUND TO THE INNOVATION

A convenient solar heat exchange system for pools consists of a mat of tubing that connects to inlet and outlet manifolds. Such a system is described in U.S. Pat. No. 4,354,546 and in U.S. Pat. No. 4,823,771. The tubing mats are laid out and bent so that the inlet and out let manifolds are adjacent each other. In the most commonly used systems of this kind, the ends of the tubes in the mat are inserted into holes drilled in the manifold and adhered using an adhesive or sealant.

U.S. Pat. No. 5,582,238 discloses a return manifold that avoid the need to loop or fold the matting in order to have the inlet and out let adjacent each other. Australian Design registrations 106573 and 106574 disclose molded manifolds with spigots onto which the tube ends can be fitted. In use these spigots are exposed to UV radiation and over time become brittle and can break away from the manifold. Australian application 2004100828 discloses a manifold kit which consists of a manifold having groups of spigots each spigot receiving the end of a heat exchange tube and a connector which groups the tubes for easy connection to each group of spigots.

A difficulty with all these systems is that if the tubes are not cut squarely the ends of the tubes will tend to be pushed too far onto the spigots distorting the ends of the tubes and results in a poor seal between the tubes and the spigots. This results in leaks and water loss at the manifolds.

It is an object of this innovation to reduce the risk of leaks at the manifolds.

BRIEF DESCRIPTION OF THE INNOVATION

To this end there is provided a manifold for a heat exchanger of the tube type which manifold includes at least one group of spigots wherein the group of spigots comprise a base fitted to the manifold, a planar region on said base and a plurality of tubular spigots projecting from said planar region.

The provision of the planar region at the base of the tubular spigots reduces the likelihood of incorrect fitting which can result in leaks at the manifold connection. The solar heat exchanger of this invention includes a mat of parallel tubes in which groups of tubes are connected to one end of a connector and the opposite end of the connector is connected to a group of spigot tubes on the manifold, said manifold having at least one group of spigots tubes and each group of spigots comprise a base fitted to the manifold and a planar region on said base and a plurality of tubular spigots project from said planar region. Preferably each mat of tubes has 15 tubes and each manifold has 5 groups of spigots, with three spigots in each group.

This manifold is used in a manifold kit for the tube type heat exchanger. The manifold kit of this invention includes

-   -   a) a manifold having at least one group of spigots tubes     -   b) each group of spigots comprise a base fitted to the manifold         a planar region on said base and a plurality of tubular spigots         projecting from said planar region and     -   c) a connector adapted to receive a group of heat exchanger         tubes in one end and adapted at the other end to connect to said         group of spigot tubes on the manifold.

This arrangement avoids the need for special tools or drilling of the manifold and the group of heat exchanger tubes can be easily fitted with the connectors and then snapped onto the manifold. The connector shields the spigots from the weather and also spreads the load across the group of spigots resulting in a longer lasting more robust system. The connector is shaped to accommodate the spigot base and the planar region at the base of the group of spigots.

The group may be two or more but to suit the commonest form of heat exchange mats three is preferred. Thus each manifold may incorporate one or more groups of three spigot tubes and the connector is able to accommodate 3 heat exchanger tubes and to be a snap fit onto a group of three spigot tubes. Larger groups may be used but with increasing size it becomes more difficult to clip the connector to the manifold.

DETAILED DESCRIPTION OF THE INNOVATION

A preferred embodiment will now be described with reference to the drawings in which:

FIG. 1 is a plan view of a manifold according to a preferred embodiment;

FIG. 2 is detail of a spigot group of the manifold of FIG. 1;

FIG. 3 is schematically shows tubes fitted to the spigot tubes of FIG. 2;

FIG. 4 is a perspective view of the spigot end of a connector according to a preferred embodiment;

FIG. 5 is a view of the tube end of a connector according to a preferred embodiment;

FIG. 6 is a side cross section of the connector of FIGS. 4 and 5;

FIG. 7 is a end view of the spigot end of the connector of FIGS. 4 and 5;

FIG. 8 shows the connector of FIG. 5 assembled to the manifold spigot group of FIG. 2.

The manifold and connector set is used with heat exchange mats of the kind described in U.S. Pat. Nos. 4,354,546 and 4,823,771 the content of which is incorporated herein by reference.

Each manifold is 500 mm in length and may be connected together by the end 11 fitting into the end 12 so that the pin 13 aligns with the slot 14.

The spigot tubes 16 are formed in groups of 3 in a block 18 moulded into the outer surface of the manifold 10. The spigots are ribbed with concentric ribs 17 to ensure that the heat exchanger tubes are secured to the spigots and form a tight seal. The block 18 includes a planar platform 19 which is large enough to accommodate the thickness of the tubing around the spigot tubes 16.

The connector 30 has a tube end 31 so that heat exchanger tubes can be fed into the tube guides 32. The spigot end of connector 30 provides a connector shroud 35 which is adapted to fit over the block 18 of the group of spigot tubes 16 on the manifold 10 and snap over the edge of the platform 19.

The spigot tubes 16 extend into the tube guides 32 so that the tube ends are wedged between the spigots 16 and the guide walls 32. The cover plate 36 provides leverage for applying and removing the connector.

The connectors can be assembled to the heat exchange mats on site or at the production factory. Once they are connected to the heat exchanger tubes and the manifolds have been installed the connection of the mat tubes to the manifolds is quick and easy snap on operation.

The manifold and connectors can be made from any suitable polymeric material preferably one that is UV and weather resistant.

From the above it can be seen that the present innovation provides a convenient and easy system of installation compared to the conventional practice.

Those skilled in the art will appreciate that this invention can be implemented in a range of embodiments, other than those described, without departing from the essential concept of grouping the heat exchange tubes and connecting these with a connector adapted to groups of spigot tubes on the manifold. 

1. A solar heat exchanger which includes a mat of parallel tubes in which groups of tubes are connected to one end of a connector and the opposite end of the connector is connected to a group of spigot tubes on a manifold said manifold having at least one group of spigots tubes and each group of spigots comprise a base fitted to the manifold and a planar region on said base and a plurality of tubular spigots projecting from said planar region.
 2. A solar heat exchanger as claimed in claim 1 in which each mat of tubes has 15 tubes and each manifold has 5 groups of spigots with three spigots in each group.
 3. A manifold kit for a solar heat exchanger of the tube type which includes d) a manifold having at least one group of spigots tubes e) each group of spigots comprise a base fitted to the manifold a planar region on said base and a plurality of tubular spigots projecting from said planar region and f) a connector adapted to receive a group of heat exchanger tubes in one end and adapted at the other end to connect to said group of spigot tubes on the manifold.
 4. A manifold kit as claimed in claim 1 in which each manifold has 5 groups of spigots with three spigots in each group.
 5. A manifold kit as claimed in claim 2 in which each group of spigots is arranged in a block and the connector is adapted to clip onto the block and enclose the spigot tubes.
 6. A manifold for a heat exchanger of the tube type which manifold includes at least one group of spigots wherein the group of spigots comprise a base fitted to the manifold a planar region on said base and a plurality of tubular spigots projecting from said planar region. 